Rotary electric machine, method for manufacturing rotary electric machine, drive device for hybrid vehicle, and method for manufacturing drive device for hybrid vehicle

Abstract

In a rotary electric machine (40), an annular holding part (12, 12B) that holds a rotor (20) is connected to a rotating shaft, and a rotor shaft part (10) that rotates together with the rotor (20) is configured. The rotor shaft part (10) comprises a groove part (12GR) recessed from the circumferential surface to one side in the radial direction, and a wall surface (12W) extending from the circumferential surface to the other side in the radial direction, on the circumferential surface on one side on the radial outer side or the radial inner side. A sensor rotor (50R) is disposed to be fitted to the circumferential surface, and an annular press-fitting member (60) is disposed to sandwich the sensor rotor (50R) from the axial direction with the wall surface (12W). The press-fitting member (60) is provided with a first protrusion (60PR) that protrudes in advance, and the press-fitting member (60) and the rotor shaft part (10) are engaged and fixed in a state in which the first protrusion (60PR) is fitted into the groove part (12GR) .

Description

Rotating electric machine, manufacturing method of rotating electric machine, drive device for hybrid vehicle, and manufacturing method of drive device for hybrid vehicle

[0001] The present application relates to a rotating electric machine, a method for manufacturing a rotating electric machine, a hybrid vehicle drive device, and a method for manufacturing a hybrid vehicle drive device.

[0002] A common method for fixing a sensor rotor of a rotational angle sensor incorporated into the rotor of a rotating electric machine is to press-fit a fixing ring onto the rotor shaft and then axially sandwich the sensor rotor between the fixing ring and the rotor shaft. However, in recent rotating electric machines constituting vehicle-mounted drive systems, the diameter of the rotating electric machine has increased in line with the increasing output, requiring a larger diameter rotational angle sensor. Furthermore, in vehicle-mounted drive systems, outer rotor-type rotational angle sensors are increasingly adopted due to layout considerations. This has resulted in larger diameter and heavier sensor rotors, making it difficult to fix the sensor rotor with the pressing force and frictional force of the conventional fixing ring. Therefore, a fixing structure for a rotational angle sensor of a rotating electric machine has been disclosed in which an elastic member is sandwiched between the fixing ring and the sensor rotor to improve frictional force in order to compensate for the fixing force of the sensor rotor (see, for example, Patent Document 1).

[0003] JP 2007-64870 A

[0004] However, in the fixing structure of the rotation angle sensor of the conventional rotating electric machine described above, the sensor rotor is fixed using an elastic member and a fixing ring, so it is necessary to secure space for both the elastic member and the fixing ring, which further creates problems such as increased costs and complicated structure and manufacturing processes.

[0005] The present application discloses technology for solving the above-mentioned problems, and aims to provide a rotating electric machine that is space-saving, low-cost, and has a simple structure while ensuring strong fixation of the sensor rotor, a method for manufacturing a rotating electric machine, a hybrid vehicle drive device equipped with this rotating electric machine, and a method for manufacturing a hybrid vehicle drive device.

[0006] The rotating electric machine disclosed in the present application is a rotating electric machine including a sensor for detecting rotation of a rotor that rotates integrally with a rotating shaft, wherein an annular holding portion that holds the rotor is connected to the rotating shaft to form a rotor shaft portion that has the holding portion and rotates together with the rotor, the rotor shaft portion having a groove portion recessed radially from the circumferential surface on one side of the radially outer or radially inner side of the rotor shaft portion, and a wall surface extending radially from the circumferential surface to the other side, a sensor rotor of the sensor is fitted into the circumferential surface and is disposed in axial contact with the wall surface, and an annular press-fit member that axially sandwiches the sensor rotor between the wall surface and is disposed in fit with the circumferential surface, the press-fit member having a first protrusion protruding from a first surface facing the circumferential surface of the rotor shaft portion, the first surface being press-fitted axially against the circumferential surface of the rotor shaft portion so that the first protrusion is fitted into the groove portion, and the press-fit member and the rotor shaft portion are engaged and fixed together. The hybrid vehicle drive device disclosed in the present application is a hybrid vehicle drive device including a rotating electric machine configured as described above and an engine, wherein the rotating electric machine is disposed such that the holding portion of the rotor of the rotating electric machine is connected to a rotating shaft that is a power transmission mechanism connecting the engine and the transmission so that the rotor is sandwiched between the transmission and the engine that are aligned in the axial direction, and a clutch mechanism that connects and disconnects power transmission is provided on at least one of an end of the rotating shaft on the engine side or an end of the rotating shaft on the transmission side.The present application also discloses a method for manufacturing a rotating electric machine, the method comprising: connecting an annular holding portion for holding a rotor that rotates integrally with a rotating shaft to the rotating shaft, and configuring a rotor shaft portion that has the holding portion and rotates together with the rotor; the rotor shaft portion has, on a circumferential surface on one side, either radially outside or radially inside, a groove portion recessed from the circumferential surface toward one radial direction, and a wall surface extending from the circumferential surface toward the other radial direction; a sensor rotor of a sensor that detects rotation of the rotor is fitted into the circumferential surface and disposed in axial contact with the wall surface; and an annular press-fit member that axially sandwiches the sensor rotor between the sensor rotor and the wall surface is fitted into the circumferential surface, the method comprising: a press-fitting step of press-fitting the press-fit member from the axial side while fitting a first surface of the press-fit member, the first surface facing the circumferential surface of the rotor shaft portion, against the circumferential surface of the rotor shaft portion, and a state in which a portion of the first surface side of the press-fit member is fitted into the groove while the press-fit member is abutting against the sensor rotor, thereby engaging and fixing the press-fit member to the rotor shaft portion. Also, a manufacturing method for a hybrid vehicle drive device disclosed in the present application is a manufacturing method for a vehicle drive device configured as described above, comprising the steps of: connecting the holding portion of the rotor of the rotating electric machine to a rotating shaft that is a power transmission mechanism connecting the engine and the transmission so that the rotating electric machine is sandwiched between the transmission and the engine, which are arranged axially; and providing a clutch mechanism that interrupts power transmission on at least one of an end of the rotating shaft on the engine side or an end of the rotating shaft on the transmission side.

[0007] The rotating electric machine and hybrid vehicle drive device disclosed herein can provide a rotating electric machine and hybrid vehicle drive device that are space-saving, low-cost, and simple in structure while ensuring strong fixation of the sensor rotor. Furthermore, the manufacturing method for the rotating electric machine and the manufacturing method for the hybrid vehicle drive device disclosed herein can provide a rotating electric machine and hybrid vehicle drive device that are space-saving, low-cost, and simple in structure while ensuring strong fixation of the sensor rotor.

[0008] 1 is a cross-sectional view schematically showing a power transmission system including a rotating electric machine that constitutes a drive device portion of a hybrid vehicle drive device according to a first embodiment; FIG. 2 is a cross-sectional view showing a partially enlarged mounting portion of a rotation sensor in the hybrid vehicle drive device according to the first embodiment; FIG. 3 is a cross-sectional view showing a partially enlarged mounting portion of a rotation sensor in the hybrid vehicle drive device according to the first embodiment; FIG. 4 is a cross-sectional view showing a partially enlarged mounting portion of a rotation sensor in the hybrid vehicle drive device according to the first embodiment; FIG. 5 is a cross-sectional view showing a partially enlarged mounting portion of a rotation sensor in the hybrid vehicle drive device according to the first embodiment; FIG. 6 is a cross-sectional view showing a partially enlarged mounting portion of a rotation sensor in the hybrid vehicle drive device according to the second embodiment; FIG. 7 is a cross-sectional view showing a partially enlarged mounting portion of a rotation sensor in the hybrid vehicle drive device according to the second embodiment;

[0009] Embodiment 1. This embodiment relates to a hybrid vehicle drive system and a rotating electric machine that constitutes the drive system portion thereof, and particularly to a mounting configuration of a rotation angle sensor to the rotating electric machine. Fig. 1 is a cross-sectional view that schematically shows a power transmission system including a rotating electric machine 40 that constitutes the drive system portion of a hybrid vehicle drive system 100 of this embodiment. Fig. 2 is a cross-sectional view that shows an enlarged view of part A in Fig. 1. Fig. 3 is a cross-sectional view that shows an enlarged view of part B in Fig. 2. In the figures, the axial and radial directions of the rotating electric machine 40 are indicated by arrows X and Y, respectively. Furthermore, the term "axially inner" refers to a position closer to the center of the rotating electric machine than both axial ends of the rotating electric machine.

[0010] The hybrid vehicle driving system 100 of this embodiment includes a rotating electric machine 40 and an on-board engine 1. The hybrid vehicle driving system 100 is also provided with a transmission 2, which is a speed change mechanism that transmits power from the engine 1 to tires, and a shaft portion 11, which is a rotating shaft and is a power transmission mechanism that connects the transmission 2 and the engine 1. The hybrid vehicle driving system 100 is configured such that the rotating electric machine 40 is located between the engine 1 and the transmission 2, which are aligned in the axial direction X. One end of the shaft portion 11 in the axial direction X is connected to the transmission 2 via a clutch mechanism 3B that connects and disconnects power transmission, and the other end is connected to the output shaft of the engine 1 via a clutch mechanism 3A that connects and disconnects power transmission.

[0011] The clutch mechanism is not limited to the configuration in which it is provided on both sides of the rotor shaft in the axial direction X with the rotating electric machine 40 at the center, but may be provided only on the engine 1 side or only on the transmission 2 side.

[0012] Next, a description will be given of the configuration of the rotating electric machine 40. As shown in Fig. 1, the rotating electric machine 40 includes an inner rotor (hereinafter simply referred to as the rotor 20) and an outer stator (hereinafter simply referred to as the stator 30) disposed concentrically with the rotor 20 and radially outward of the rotor 20.

[0013] The rotor 20 has a rotor core 20C and a magnet (not shown). The stator 30 has a stator core 30C and a coil (not shown) attached to the stator core 30C, with coil ends (not shown) protruding from the axial end face of the stator core 30C on both sides in the axial direction X. The stator 30 is attached to the inner circumferential surface of a peripheral wall 5IN of a housing 5 that houses the rotating electric machine 40.

[0014] The rotor shaft portion 10 constituting the rotating shaft of the rotor 20 of the rotating electric machine 40 is configured to include a cylindrical portion 12 serving as a holding portion for holding the rotor core 20C, the shaft portion 11 connecting the engine 1 and the transmission 2, and a connecting portion 13 connecting the shaft portion 11 and the cylindrical portion 12. The cylindrical portion 12 is formed by stacking a plurality of electromagnetic steel plates in the axial direction X, and the rotor core 20C is fixed to an outer peripheral surface 12OUT on the radially outer side of the cylindrical portion 12. The shaft portion 11 of the rotating electric machine 40 of this embodiment is shared with the drive shaft which is the rotating shaft connecting the engine 1 and the transmission 2 constituting the hybrid vehicle drive device 100 as described above.

[0015] The housing 5 has an engine cover 5W1, which is a wall surface on the other end side in the axial direction X, and a support wall 5W2 extending from the engine cover 5W1 to one side in the axial direction X. As shown in Fig. 2, a bearing 12B serving as a retaining portion is provided on the support wall 5W2 of the housing 5. Furthermore, the cylindrical portion 12 supporting the rotor 20 has a bearing connection portion 12BS extending from the cylindrical portion 12 toward the radially inward direction Y1. This bearing connection portion 12BS is connected to the bearing 12B provided on the support wall 5W2 of the housing 5, so that the rotor 20 is rotatably supported via the bearing 12B and rotates integrally with the shaft portion 11.

[0016] The rotor shaft portion 10 of the rotor 20 in this embodiment is an integrated member that includes the shaft portion 11, which is shared with the drive shaft, the cylindrical portion 12 that holds the rotor 20, and the connecting portion 13. Furthermore, the entire mechanism, including the bearing 12B and bearing connecting portion 12BS that hold the rotor 20 and support the rotor 20 rotatably around the rotation axis integrally with the rotor 20, is considered to be part of the rotor shaft portion 10.

[0017] Next, the rotation angle sensor 50 attached to the rotating electric machine 40 will be described. As shown in Fig. 2, the rotation angle sensor 50, which detects the rotation angle of the rotor 20, is configured with an annular sensor rotor 50R and an annular sensor stator 50S. The sensor stator 50S is attached near the bearing 12B on the support wall 5W2 of the engine cover 5W1. The sensor rotor 50R is attached and fixed to the inner circumferential surface 12IN of the cylindrical portion 12 in an attachment manner described in detail below so as to face the sensor stator 50S in the radial direction Y.

[0018] 1, the bearing 12B, bearing connection portion 12BS, sensor stator 50S, and sensor rotor 50R are accommodated and arranged in a space on the radially inner side Y1 of the cylindrical portion 12 of the rotating electrical machine 40. The rotation angle sensor 50 is arranged in a space within a range indicated by X1 axially inward from both axial ends of the rotor 20, and is not arranged axially outward beyond the axial ends of the rotor 20. In this way, a space-saving configuration is adopted that utilizes the space on the inner side of the cylindrical portion 12.

[0019] Next, a detailed configuration of the rotating electrical machine 40 according to the first embodiment, particularly the mounting portion of the sensor rotor 50R in the cylindrical portion 12 that holds the rotor 20, will be described with reference to Fig. 1 and Fig. 3, which shows an enlarged view of a main portion. As shown in Fig. 3, the cylindrical portion 12 that holds the rotor 20 has a step 12S formed on its inner circumferential surface 12IN, which changes the height in the radial direction Y. A wall surface that constitutes this step 12S and extends from the inner circumferential surface 12IN to the radially inward direction Y1 is referred to as a wall surface 12W.

[0020] The sensor rotor 50R is attached to the cylindrical portion 12 so that its outer peripheral surface on the radially outer side Y2 is loosely fitted with a set gap GAP relative to the inner peripheral surface 12IN of the cylindrical portion 12. An annular fixing ring 60 as a press-fit member is disposed and fixed at a predetermined position in the axial direction X so as to sandwich the sensor rotor 50R between itself and the wall surface 12W in the axial direction X. In this way, the sensor rotor 50R is fixed on the inner peripheral surface 12IN side of the cylindrical portion 12 that constitutes the rotor shaft portion 10.

[0021] The inner circumferential surface 12IN of the cylindrical portion 12 is provided with a groove 12GR for engaging and fixing the fixing ring 60. The groove 12GR is recessed radially outward Y2 from the inner circumferential surface 12IN of the cylindrical portion 12, with its depth direction being in the radial direction Y. As shown in FIG. 3 , a portion of the outer circumferential surface 60OUT, which serves as a first surface of the fixing ring 60, is inserted into the groove 12GR, so that the fixing ring 60 is engaged with the groove 12GR. In this way, the fixing ring 60 and the cylindrical portion 12 that constitutes the rotor shaft portion 10 are engaged and fixed.

[0022] In particular, in the example of the first embodiment, the part of the fixing ring 60 that fits inside the groove 12GR is made up of a protrusion 60PR as a first protrusion that was previously formed on the outer circumferential surface 60OUT of the fixing ring 60 that faces the inner circumferential surface 12IN of the cylindrical portion 12 before the fixing ring 60 was attached to the cylindrical portion 12. In other words, when the fixing ring 60 is press-fitted into the inner circumferential surface 12IN of the cylindrical portion 12, the protrusion 60PR that was previously formed on the fixing ring 60 is fitted into the groove 12GR, thereby engaging and fixing the fixing ring 60 to the cylindrical portion 12.

[0023] More specifically, the manner in which the fixing ring 60 is fixed is such that, with the sensor rotor 50R in contact with the wall surface 12W, the fixing ring 60 presses the sensor rotor 50R in the axial direction X. In other words, with the fixing ring 60 attached and fixed to the cylindrical portion 12, a compressive stress is generated that presses the sensor rotor 50R with a set pressure in the axial direction X. The positions of the fixing ring 60 and the groove portion 12GR in the axial direction X are adjusted so that a compressive stress is generated on the sensor rotor 50R.

[0024] Regarding the shape of the protrusion 60PR of the fixing ring 60, it is desirable to form an inclined surface C1 on the side surface closer to the step 12S and the sensor rotor 50R, which is the front side when the protrusion 60PR is inserted, so that the protrusion 60PR can be relatively easily inserted into the groove 12GR by press-fitting. Here, an inclined surface C3 inclined relative to the inner circumferential surface 12IN is formed on the edge of the inner wall constituting the groove 12GR, on one axial side closer to the step 12S. If a gap is formed between this inclined surface C3 and the fixing ring 60, the pressing force from the axial direction X by the fixing ring 60 pressing against the sensor rotor 50R is prevented from being dispersed toward the cylindrical portion 12, thereby ensuring reliable pressing force from the axial direction X on the sensor rotor 50R.

[0025] As described above, it is desirable to form an inclined surface C2 on the side surface of at least one of the protrusion 60PR and the groove 12GR that is farther from the step 12S and the sensor rotor 50R so that the fixing ring 60 engages with the cylindrical portion 12 while exerting a pressing action on the sensor rotor 50R in the axial direction X when the fixing ring 60 is attached and fixed to the rotor shaft portion 10. When this inclined surface C2 comes into contact with the edge portion on the other axial side of the inner wall that constitutes the groove 12GR, a pressing force that presses the sensor rotor 50R in the axial direction X is obtained.

[0026] As described above, the fitting location between the sensor rotor 50R and the inner circumferential surface 12IN of the cylindrical portion 12 is configured so that they are attached with a clearance GAP in the radial direction Y, i.e., the dimensions of the clearance fit are set to ensure a clearance GAP within the tolerance range. This is because the rotor core 20C is press-fit along the outer circumferential surface 12OUT of the cylindrical portion 12. Because this press-fitting process presses the cylindrical portion 12 radially inward Y1, the shape may change slightly before and after this process. As a result, it is expected that the positional relationship between the sensor rotor 50R, which is fitted and assembled to the inner circumferential surface 12IN of the radially inward Y1 of the cylindrical portion 12, will change. The dimensions of this clearance fit are designed to ensure a clearance GAP within each tolerance range, taking into consideration the above-mentioned change in positional relationship and manufacturing variations.

[0027] In the example of the first embodiment, the rotation angle sensor 50 is configured as an outer rotor type. That is, the example has been described in which the sensor rotor 50R is attached to the inner circumferential surface 12IN of the cylindrical portion 12 constituting the rotor shaft portion 10 by providing a step 12S and a groove 12GR, and the sensor stator 50S is provided on the radially inner side Y1 of the cylindrical portion 12. However, the rotation angle sensor 50 may be configured as an inner rotor type. That is, the sensor rotor 50R may be attached to the outer circumferential surface 12OUT of the cylindrical portion 12 constituting the rotor shaft portion 10 by providing a step 12S and a groove 12GR, and the sensor stator 50S may be provided on the radially outer side Y2 of the cylindrical portion 12.

[0028] Furthermore, an inner rotor type sensor rotor 50R may be arranged as shown in the following figure. FIG. 4 is a partially enlarged cross-sectional view of a hybrid vehicle drive device 100, showing the arrangement of the sensor rotor 50R of the rotation angle sensor 50 of this embodiment. FIG. 5 is an enlarged cross-sectional view of a main portion of the hybrid vehicle drive device 100 shown in FIG. 4. In this case, the outer peripheral surface of the annular bearing 12B constituting the holding portion of the rotor shaft portion 10 may be provided with a groove 12GR recessed radially inward (Y1), as shown in FIG. 5, to fix the sensor rotor 50R. In this configuration, the aforementioned step 12S is not formed, but the wall surface 12BSW of the bearing connection portion 12BS extending radially outward (Y2) from the outer peripheral surface of the bearing 12B determines the axial position of the sensor rotor 50R. A fixing ring 60 is disposed and fixed at a predetermined position in the axial direction X so as to sandwich the sensor rotor 50R between the wall surface 12BSW and the sensor rotor 50R in the axial direction X.

[0029] As described above, the sensor rotor 50R may be provided on the circumferential surface of the radially inner side Y1 or the radially outer side Y2 of each structural part that constitutes the rotor shaft portion 10. Furthermore, if the rotation angle sensor 50 is an outer rotor type, for example, a wall surface of the bearing connection portion 12BS extending in the radial direction Y may be used as a wall surface for positioning the sensor rotor 50R in the axial direction X.

[0030] Next, a method for manufacturing the rotating electric machine 40 that constitutes the drive unit portion of the hybrid vehicle drive unit 100 of this embodiment will be described, including the effects that can be obtained as appropriate. In particular, the main part of the method for attaching the rotation angle sensor 50 to the rotor shaft portion 10 of the rotating electric machine 40, which is a characteristic part of this embodiment, will be described below.

[0031] As described above in the configuration description, the method of attaching the rotation angle sensor 50 to the rotor shaft portion 10 in this embodiment will be described on the premise that the rotation angle sensor 50 is prepared in a configuration in which, on the radial inside of the cylindrical portion 12 of the rotor shaft portion 10, a step 12S having a wall surface 12W that functions to determine the attachment position of the sensor rotor 50R with respect to the axial direction X, and a groove portion 12GR with a depth direction in the radial direction Y that is provided for engaging the fixing ring 60 are provided.

[0032] First, the sensor rotor 50R is inserted in the axial direction X while being fitted onto the inner circumferential surface 12IN of the cylindrical portion 12 of the rotor shaft portion 10, and is attached to a position near the axial positioning step 12S. As described above, the rotation angle sensor 50 is attached by a state in which a portion of the fixing ring 60 is inserted and fitted into the groove 12GR. However, several methods for attaching the fixing ring 60 by fitting a portion of the outer circumferential surface 60OUT side into the groove 12GR are conceivable. In the first embodiment, the following method is used as a first example of a press-fitting step for fitting a portion of the outer circumferential surface 60OUT side of the fixing ring 60 into the groove 12GR.

[0033] First, a first convex portion forming process is performed to prepare the fixing ring 60 having a convex portion 60PR on the outer circumferential surface 60OUT before attachment to the rotor shaft portion 10. In this first convex portion forming process, the convex portion 60PR is formed at a position on the outer circumferential surface 60OUT that faces the groove portion 12GR when the fixing ring 60 abuts against the sensor rotor 50R.

[0034] Then, the fixing ring 60 provided with the protrusions 60PR is inserted from the axial direction X along the inner circumferential surface 12IN of the cylindrical portion 12 of the rotor shaft portion 10, and a press-fitting process is performed in which the fixing ring 60 is press-fitted from the axial direction X to a position where the sensor rotor 50R abuts against the step 12S of the rotor shaft portion 10. As a result, the protrusions 60PR of the fixing ring 60 are pressed into the inner circumferential surface 12IN of the cylindrical portion 12 in a press-fit state, and the protrusions 60PR are pressed into the grooves 12GR of the cylindrical portion 12 and locked, thereby fixing the axial position. At this time, a large repulsive force is generated in the axial direction X at the protrusions 60PR, which acts as a set compressive stress on the sensor rotor 50R and becomes a frictional force that prevents the sensor rotor 50R from rotating about its rotation axis.

[0035] With this mounting method, the fixing ring 60, the sensor rotor 50R, and the rotor shaft 10 can be simultaneously fixed simply by applying a load in the axial direction X, and because the fixing ring 60 is engaged with the cylindrical portion 12 of the rotor shaft 10, movement of the sensor rotor 50R in the axial direction X can be physically restricted, preventing the sensor rotor 50R from falling off. Furthermore, with the fixing ring 60 fixed to the cylindrical portion 12 of the rotor shaft 10, a compressive stress is generated that presses the sensor rotor 50R in the axial direction X. This allows a relatively large frictional force to be generated at the contact surface between the cylindrical portion 12 of the rotor shaft 10 and the sensor rotor 50R, which also acts to restrict rotation of the fixing ring 60 about the rotation axis.

[0036] Furthermore, as explained above, when the fixing ring 60 is attached to the cylindrical portion 12 of the rotor shaft portion 10 by press-fitting and locking, the combined effect of the clearance fit at the mating portion between the sensor rotor 50R and the cylindrical portion 12 is such that the dimensional tolerances are set to provide a clearance GAP even after the rotor core 20C is press-fitted and fixed to the outer peripheral surface 12OUT side of the cylindrical portion 12. This makes it possible to avoid performance degradation due to deformation of the sensor rotor 50R and compressive stress.

[0037] Furthermore, even in the process of attaching the sensor rotor 50R to a position near the step 12S, which is a stage before the sensor rotor 50R is fixed by the fixing ring 60, the dimensions of both are designed to always provide a gap between them in the radial direction Y. This makes it easy to attach the sensor rotor 50R without it getting caught midway when moving in the axial direction X. In particular, when the rotor installation process is performed in which the rotor 20 is press-fitted into the outer peripheral surface 12OUT on the radially outer side of the cylindrical portion 12 of the rotor shaft portion 10, the shape of the cylindrical portion 12 may change before and after this process. Therefore, the sensor rotor 50R is sandwiched between the fixing ring 60 and the wall surface 12W at a position where it is in a clearance fit with the inner peripheral surface 12IN of the cylindrical portion 12.

[0038] Next, a brief description will be given below of the manufacturing method for manufacturing the final hybrid vehicle drive device after going through the manufacturing method for the rotating electric machine 40 in the first embodiment and the modified examples described above, and the resulting effects.

[0039] In the rotating electric machine manufactured by the manufacturing method of the rotating electric machine 40 in the first embodiment and the modified example, the rotating electric machine 40 is positioned in a position sandwiched between the engine 1 and the transmission 2 in the axial direction X, and the rotor 20 in the rotating electric machine 40, in particular the rotor shaft portion 10 constituting the rotating shaft, is connected to a drive shaft which serves as a power transmission mechanism between the transmission 2 and the engine 1.

[0040] In addition, when a configuration is adopted in which a portion of the rotor shaft portion 10 also serves as a drive shaft, as in the configuration of embodiment 1, a process of assembling a portion of the rotor 20 equipped with a rotation angle sensor to the drive shaft may be performed. In the example of embodiment 1, a drive shaft in which a connecting member and a shaft portion are integrated is assembled to the cylindrical portion 12 constituting the rotor shaft portion 10 of the rotor 20. Furthermore, a process of assembling a clutch mechanism to the rotating electric machine 40 is performed. The clutch mechanism is assembled so as to be disposed on either the engine side or the transmission side. Alternatively, when a configuration is adopted in which clutch mechanisms are disposed on both the engine side and the transmission side, it is only necessary to perform a process of assembling the clutch mechanism on both the engine side and the transmission side.

[0041] The order in which the above steps are performed can be optimized as appropriate, taking into consideration the ease of assembly of each component to be assembled, the convenience of using components in common, etc., and by appropriately combining and going through each of the above steps, the hybrid vehicle drive device of this embodiment can be completed, that is, manufactured.

[0042] The hybrid vehicle drive system and its manufacturing method described above enable the rotation angle sensor to be securely fixed to the rotating electric machine, structurally preventing the sensor rotor from moving axially, reducing component and manufacturing costs, and simplifying the structure and manufacturing process. Furthermore, when an outer rotor-type sensor rotor with a relatively large diameter and weight is used, even the heavy sensor rotor can be securely and reliably fixed. As a result, the manufacturing method for the hybrid vehicle drive system as a whole provides an excellent manufacturing method that combines various effects, such as significantly reducing manufacturing costs and achieving high levels of reliability and space efficiency, both of which are highly required for vehicle drive systems.

[0043] Furthermore, the drive shaft, which transmits rotational torque between the output shaft of the vehicle engine and the transmission, and the rotor shaft, which constitutes the rotating shaft of the rotor of the rotating electric machine, are shared. The rotation angle sensor is located within a set range axially inward from both axial ends of the rotor, but is not located axially outward from the axial ends of the rotor. That is, the bearing portion serving as a retaining portion, the sensor stator of the rotation angle sensor, and the sensor rotor are housed within the space inside a cylindrical portion serving as a retaining portion that constitutes part of the rotor shaft. Therefore, in a hybrid vehicle drive system where spatial constraints are significant due to the need to arrange the clutch, rotating electric machine, rotation angle sensor, etc. in the narrow space between the engine and the transmission, this allows for efficient use of the space inside the rotor while simultaneously achieving high motor output. This is an effect common to both the outer rotor type and the inner rotor type, which is an example of a modified version.

[0044] Furthermore, in the case of an outer rotor type rotation angle sensor, the sensor rotor is fitted onto the inner peripheral surface of the cylindrical portion that holds the rotor core, which not only makes efficient use of space as described above, but also allows the outer rotor type sensor rotor, which is relatively large in diameter and heavy, to be fixed relatively firmly and reliably, and also makes it possible to reduce manufacturing costs.In addition, because the rotor is rotatably supported by the support wall of the housing via the bearing connection portion and the bearing, stable rotation can be ensured even if the rotor is heavy.

[0045] Embodiment 2. Hereinafter, Embodiment 2 of the present invention will be described with reference to the drawings, focusing on the differences from Embodiment 1 described above. The same parts as those in Embodiment 1 above are assigned the same reference numerals, and a description thereof will be omitted. In Embodiment 2, the method described below is used as a second example of the press-fitting process for fitting a portion of the outer circumferential surface 60OUT side of the fixing ring 60 into the groove portion 12GR. Figure 6 is an enlarged partial cross-sectional view of a hybrid vehicle drive device, showing the arrangement of the sensor rotor 50R of the rotation angle sensor 50 of this embodiment.

[0046] In this alternative mounting method, similar to the method described in the first embodiment, the sensor rotor 50R is first inserted from the axial direction X along the inner circumferential surface 12IN of the cylindrical portion 12 of the rotor shaft portion 10, and positioned so as to abut against the step 12S of the rotor shaft portion 10. Note that the fitting portion between the sensor rotor 50R and the cylindrical portion 12 of the rotor shaft portion 10 is set to be a clearance fit, and therefore, in the step of mounting the sensor rotor 50R to a position near the step 12S of the cylindrical portion 12, the sensor rotor 50R is easily attached, just like the mounting method described above.

[0047] Next, with the fixing ring 60 in contact with the sensor rotor 50R, as shown in Figure 6, the annular fixing ring 60 is pressed and deformed from the surface on the side that contacts the sensor rotor 50R and the surface on the side opposite to the axial direction X using a tool 70 having an acute angle. At this time, it is desirable that the pressing position is radially outward from the center of the cross section of the fixing ring 60 as shown in the figure. By causing a flow point 60FL generated by this deformation to bite into the groove portion 12GR, a portion of the outer peripheral surface 60OUT side of the fixing ring 60 is fitted inside the groove portion 12GR.

[0048] In particular, as described above, the flow location 60FL can be more easily fitted into the groove portion 12GR by pressing the tool 70 radially outward from the center of the cross section of the fixing ring 60. As a result, the fixing ring 60 is locked and fixed to the cylindrical portion 12 of the rotor shaft portion 10 while pressing against the sensor rotor 50R.

[0049] Note that the fixing ring 60 is deformed by being pressed in the axial direction X, causing a flow portion 60FL, which is a portion of its outer circumferential surface 60OUT side, to fit into the groove 12GR. This eliminates the need for the first convex portion forming step of forming a convex portion 60PR, as in the previously described method. This alternative mounting method also presses the fixing ring 60 in the axial direction X toward the sensor rotor 50R, causing a portion of the outer circumferential surface 60OUT side of the fixing ring 60 to fit into the groove 12GR, thereby securing the sensor rotor 50R. This results in a structure in which the fixing ring 60 presses the sensor rotor 50R in the axial direction X when the sensor rotor 50R is installed in contact with the wall surface 12W. In other words, when the fixing ring 60 is attached and fixed to the cylindrical portion 12, a compressive stress is generated that presses the sensor rotor 50R with a set pressure in the axial direction X. This achieves a configuration similar to that achieved when the previously described press-fitting method for securing the sensor rotor 50R is used. As a result, the rotation of the fixing ring 60 is also suppressed.

[0050] With this manufacturing method, there is no need to provide a first convex portion forming process for forming convex portions 60PR and the like on the outer periphery of the fixing ring 60 in advance, thereby reducing component costs, and manufacturing is easier because there is no need to strictly control the positional relationship in the axial direction X between the convex portion 60PR and the groove portion 12GR.

[0051] Another desirable embodiment of the manufacturing method will be described. FIG. 7 is an enlarged cross-sectional view of a portion of a hybrid vehicle drive device, showing the arrangement of the sensor rotor 50R of the rotation angle sensor 50 according to this embodiment. In this example, with regard to the setting of tolerances in the axial direction X for the positions of the sensor rotor 50R, the fixing ring 60, the groove 12GR, and the like, it is desirable to adopt a configuration in which the position of the groove 12GR of the rotor shaft portion 10 is within the fitting range with the fixing ring 60 (L1<L2), as shown in FIG. 7 . This prevents the flow portion 60FL, which occurs when the tool 70 is pressed, from entering the groove 12GR and escaping in the axial direction X, thereby suppressing insufficient and variation in fixing force.

[0052] Below, we will explain modifications of the above manufacturing method, with some modifications. FIG. 8 is a partially enlarged cross-sectional view of a hybrid vehicle drive device, showing the arrangement of the sensor rotor 50R of the rotation angle sensor 50 according to this embodiment. In this first modification, the sensor rotor 50R has a plurality of through holes 50RH penetrating in the axial direction X on the surface facing the fixing ring 60. Furthermore, as shown in FIG. 8 , the fixing ring 60 is pressed with a tool 70 from near the center of each through hole 50RH, along an extension of the axial direction X. As a result, when the fixing ring 60 is deformed, a portion of the fixing ring 60 facing the sensor rotor 50R forms a flowing portion 60FL2, which bites into the through hole 50RH, becoming embedded in the through hole 50RH. As a result, the fixing ring 60 is locked to the sensor rotor 50R.

[0053] This locking prevents the rotational movement of the sensor rotor 50R not only by frictional force from the fixing ring 60 but also physically, thereby completely fixing the sensor rotor 50R and rotor shaft portion 10 in the axial and rotational directions via the fixing ring 60.

[0054] FIG. 9 is a partially enlarged cross-sectional view of a hybrid vehicle drive device showing the arrangement of the sensor rotor 50R of the rotation angle sensor 50 according to this embodiment. In the second modified example, the through-holes 50RH in the rotor 20 of the rotating electric machine are replaced with recesses 50RGR, which are holes, as compared to the first modified example. Specifically, because the sensor rotor 50R is made of laminated electromagnetic steel sheets, the recesses 50RGR can be formed by drilling holes in only one of the laminated steel sheets (the cut core) that contacts the fixing ring 60, as shown in FIG. 9 . This has the advantage of extending the life of the mold compared to drilling holes in all steel sheets. In particular, if a straight portion perpendicular to the circumferential direction, which is effective for locking in the rotational direction, is formed in the recesses 50RGR, corners are created, which can easily accelerate mold wear. For this reason, drilling holes only in the cut core is also effective in improving the flexibility of the shape of the recesses 50RGR.

[0055] While the above example illustrates the formation of the recesses 50RGR by drilling a hole in only one of the laminated steel plates, the recesses 50RGR may also be formed by drilling through holes in at least a set number of steel plates constituting the other axial side of the sensor rotor. Furthermore, the above example illustrates the method of pressing the tool 70 against the fixing ring 60 to deform the fixing ring 60, thereby causing the flow portion 60FL2 to fit into the through-hole 50RH or the recesses 50RGR. However, this is not limiting. For example, a second protrusion forming step may be performed to previously provide a second protrusion on the surface of the fixing ring 60 corresponding to the sensor rotor 50R on one axial side, and then the second protrusion may be pressed into the through-hole 50RH or the recesses 50RGR in the press-fit step.

[0056] In this embodiment as well, it is possible to ensure strong fixation of the sensor rotor, structurally reliably prevent the sensor rotor from moving axially, reduce component costs and manufacturing costs, and simplify the structure and manufacturing process.

[0057] Although various exemplary embodiments and examples are described in this application, the various features, aspects, and functions described in one or more embodiments are not limited to the application of a particular embodiment, but may be applied to the embodiments alone or in various combinations. Therefore, countless modifications not illustrated are contemplated within the scope of the technology disclosed in this application. For example, this includes cases where at least one component is modified, added, or omitted, or where at least one component is extracted and combined with components of another embodiment.

[0058] 1 Engine, 2 Transmission, 3A, 3B Clutch mechanism, 10 Rotor shaft, 12 Cylindrical portion (holding portion), 12B Bearing (holding portion), 12W Wall surface, 20 Rotor, 60OUT Outer circumferential surface (first surface), 60PR Convex portion (first convex portion), 50R Sensor rotor, 100 Hybrid vehicle drive device.

Claims

1. In a rotating electrical machine provided with a sensor for detecting the rotation of a rotor that rotates integrally with a rotating shaft, an annular holding portion that holds the rotor is connected to the rotating shaft, and a rotor shaft portion that has the holding portion and rotates together with the rotor is configured, the rotor shaft portion includes, on a circumferential surface on one side of the radially outer side or the radially inner side of the rotor shaft portion, a groove portion that is recessed from the circumferential surface toward one side in the radial direction, and a wall surface that extends from the circumferential surface toward the other side in the radial direction, a sensor rotor of the sensor is disposed in contact with the wall surface from the axial direction while being fitted to the circumferential surface, an annular press-fitting member that axially sandwiches the sensor rotor between the sensor rotor and the wall surface is fitted to the circumferential surface, the press-fitting member has a first convex portion protruding in advance on a first surface facing the circumferential surface of the rotor shaft portion, and the first surface is press-fitted axially against the circumferential surface of the rotor shaft portion so that the first convex portion is fitted into the groove portion, and the press-fitting member and the rotor shaft portion are engaged and fixed, Rotating electrical machine.

2. The axial position of the first convex portion of the press-fitting member and the groove portion is adjusted so that the press-fitting member applies an axial compressive stress to the sensor rotor. The rotating electrical machine according to claim 1.

3. An edge portion of an inner wall constituting the groove portion forms an inclined surface portion that is inclined with respect to the circumferential surface on the wall surface side, which is one side in the axial direction, and a gap is formed between the inclined surface portion and the press-fitting member. The rotating electrical machine according to claim 1.

4. An edge portion of an inner wall constituting the groove portion forms an inclined surface portion that is inclined with respect to the circumferential surface on the wall surface side, which is one side in the axial direction, and a gap is formed between the inclined surface portion and the press-fitting member. The rotating electrical machine according to claim 2.

5. The press-fitting member has a second convex portion protruding in advance on a surface on the side opposite to the sensor rotor, which is one side in the axial direction, the sensor rotor has a hole portion formed on a surface on the side opposite to the second convex portion, which is the other side in the axial direction, the press-fitting member and the sensor rotor are engaged and fixed in a state where the second convex portion of the press-fitting member is fitted into the hole portion of the sensor rotor. The rotating electrical machine according to claim 1.

6. The press-fitting member has a second convex portion protruding in advance on a surface on the side opposite to the sensor rotor, which is one side in the axial direction, the sensor rotor has a hole portion formed on a surface on the side opposite to the second convex portion, which is the other side in the axial direction, The press-fitting member and the sensor rotor are engaged and fixed in a state where the second convex portion of the press-fitting member is fitted into the hole portion of the sensor rotor. The rotating electrical machine according to claim 2.

7. The press-fitting member is provided with a second convex portion protruding in advance on the surface on the side facing the sensor rotor, which is one side in the axial direction. The sensor rotor has a hole portion formed on the surface on the side facing the second convex portion, which is the other side in the axial direction. The press-fitting member and the sensor rotor are engaged and fixed in a state where the second convex portion of the press-fitting member is fitted into the hole portion of the sensor rotor. The rotating electrical machine according to claim 3.

8. The axial width of the groove portion is configured to be smaller than the axial width of the press-fitting member. The rotating electrical machine according to claim 1.

9. The axial width of the groove portion is configured to be smaller than the axial width of the press-fitting member. The rotating electrical machine according to claim 2.

10. The axial width of the groove portion is configured to be smaller than the axial width of the press-fitting member. The rotating electrical machine according to claim 3.

11. In a configuration where the groove portion and the wall surface are provided on the circumferential surface inside the radial direction of the rotor shaft portion. The sensor rotor is disposed axially inside the both axial ends of the rotor. The rotating electrical machine according to claim 1.

12. A drive device for a hybrid vehicle comprising the rotating electrical machine according to any one of claims 1 to 11, and an engine. The rotating electrical machine is a power transmission mechanism connecting the engine and the transmission, and the holding portion of the rotor of the rotating electrical machine is connected and disposed on a rotating shaft such that the rotor is sandwiched between the transmission arranged axially and the engine. The rotating shaft is provided with a clutch mechanism portion for interrupting power transmission at at least one of the end portion on the engine side or the end portion on the transmission side. Drive device for a hybrid vehicle.

13. An annular holding portion for holding a rotor rotating integrally with the rotating shaft is connected to the rotating shaft, and a rotor shaft portion having the holding portion and rotating together with the rotor is configured. The rotor shaft portion includes, on one circumferential surface of the rotor shaft portion, either the outer side or the inner side in the radial direction, a groove portion recessed from the circumferential surface toward one side in the radial direction, and a wall surface extending from the circumferential surface toward the other side in the radial direction. ​ A sensor rotor of a sensor for detecting rotation of the rotor is disposed in contact with the wall surface from the axial direction while being fitted to the circumferential surface, An annular press-fitting member that axially sandwiches the sensor rotor between the wall surface is fitted and disposed on the circumferential surface. A method for manufacturing a rotating electrical machine, A press-fitting step of press-fitting a first surface of the press-fitting member facing the circumferential surface of the rotor shaft portion into the circumferential surface of the rotor shaft portion from the axial side while fitting, bringing the press-fitting member into contact with the sensor rotor, and fitting a part of the first surface side of the press-fitting member into the groove portion to engage and fix the press-fitting member and the rotor shaft portion. A method for manufacturing a rotating electrical machine.

14. A first convex portion forming step of previously forming a first convex portion at a position of the first surface facing the groove portion when the press-fitting member contacts the sensor rotor is provided before the press-fitting step. In the press-fitting step, By pushing the first convex portion into the groove portion, the first convex portion as a part of the first surface side is fitted into the groove portion. The method for manufacturing a rotating electrical machine according to claim 13.

15. In the press-fitting step, In a state where the press-fitting member is in contact with the sensor rotor, the press-fitting member is pressed from the surface on the side opposite to the axial direction of the surface of the press-fitting member that contacts the sensor rotor, and the press-fitting member is deformed by the pressing so that a part of the first surface side bites into the groove portion, and the part of the first surface side is fitted into the groove portion. The method for manufacturing a rotating electrical machine according to claim 13.

16. In a configuration in which the sensor rotor has a hole portion on a surface facing the press-fitting member on the other axial side, A second convex portion forming step of previously forming a second convex portion on a surface of the press-fitting member facing the hole portion of the sensor rotor on one axial side is provided before the press-fitting step. In the press-fitting step, By pushing the second convex portion into the hole portion, the second convex portion is fitted into the groove portion. The method for manufacturing a rotating electrical machine according to any one of claims 13 to 15.

17. In a configuration in which the sensor rotor has a hole portion on a surface facing the press-fitting member on the other axial side, Press the press-fitting member from the surface on the side facing the sensor rotor of the press-fitting member and the surface on the side opposite to the axial direction, and deform the press-fitting member by this pressing so that a part of the press-fitting member on the side facing the sensor rotor bites into the hole portion, and make a part on the side facing the sensor rotor fit into the hole portion. The method for manufacturing a rotating electrical machine according to claim 13.

18. In a configuration in which the groove portion and the wall surface are provided on the circumferential surface inside the radial direction of the rotor shaft portion, In the press-fitting step, The sensor rotor is sandwiched between the wall surface and the press-fitting member at a position where the sensor rotor is in a clearance fit state with respect to the circumferential surface inside the radial direction of the rotor shaft portion. The method for manufacturing a rotating electrical machine according to claim 13.

19. In a configuration in which the sensor rotor has a hole portion on the surface facing the press-fitting member on the other side in the axial direction, The sensor rotor is formed by stacking a plurality of steel plates in the axial direction, By forming through holes in at least a set number of the steel plates that constitute the other side in the axial direction of the sensor rotor among the plurality of steel plates, the hole portion is formed. The method for manufacturing a rotating electrical machine according to claim 13.

20. A method for manufacturing a drive device for a hybrid vehicle according to claim 12, A step of connecting the holding portion of the rotor of the rotating electrical machine to a rotating shaft that is a power transmission mechanism connecting the engine and the transmission so that the rotating electrical machine is sandwiched between the transmission and the engine arranged in the axial direction; A step of providing a clutch mechanism portion for interrupting power transmission at at least one of the end on the engine side or the end on the transmission side of the rotating shaft. The method for manufacturing a drive device for a hybrid vehicle.